Elastic Nonwoven Fabric

ABSTRACT

The object of the present invention is to improve the elasticity of a nonwoven fabric manufactured by the spunbonding method.
         To attain the object, the present invention provides a nonwoven fabric manufactured by the spunbonding method, wherein a lot of holes are formed in the nonwoven fabric by the needle punching method, to give said nonwoven fabric elasticity.   Synthetic resin may be impregnated into the nonwoven fabric.

FIELD OF THE INVENTION

The present invention relates to an elastic nonwoven fabric manufacturedby the spunbonding method.

BACKGROUND OF THE INVENTION

Hitherto, as the surface layer material, a nonwoven fabric manufacturedby the needle punching method has generally been used. Nevertheless, itis difficult to manufacture a thin nonwoven fabric by the needlepunching method. Therefore, this thin nonwoven fabric has beenmanufactured by the spunbonding method. (Patent LiteratureJP2002-105832)

DISCLOSURE OF THE INVENTION

Nevertheless, the nonwoven fabric manufactured by the spunbonding methodhas poor elasticity along its length and width, so that in a case wheresaid nonwoven fabric is used as a surface layer material, and isattached to the base material and molded into a prescribed shape, thereis a problem in that wrinkles and cracks may occur in the deep drawnpart of the resulting molded fabric.

Means to Solve Said Problem

As a means to solve said problem, the present invention provides anelastic nonwoven fabric made of a nonwoven fabric manufactured by thespunbonding method, wherein a lot of holes are formed in said nonwovenfabric by the needle punching method.

It is preferable that synthetic resin be impregnated into said nonwovenfabric.

Further, it is preferable that said synthetic resin be a thermosettingresin.

Furthermore, the present invention also provides an interior materialconsisting of said elastic nonwoven fabric as a surface layer material,and a base material to whose surface said elastic nonwoven fabric isattached as a surface layer, then being molded into a prescribed shape.

Effect of the Invention

The elasticity of said nonwoven fabric along its length and width isimproved by a lot of holes formed in said nonwoven fabric by needlepunching. Accordingly, in a case where said elastic nonwoven fabric isused as a surface layer material, being attached to a base material, andmolded into a prescribed shape, no wrinkles and no cracks may occur inthe deep drawn part of the resulting molded article.

DETAILED DESCRIPTION OF THE INVENTION AND PREFERRED EMBODIMENTS

The nonwoven fabric used in the present invention is manufactured by thespunbonding method, wherein a thermoplastic resin is melted and extrudedfrom the spinning die to form a lot of filaments, and the resultingfilaments bond to each other in their melting state. A plural number ofsaid nonwoven fabrics manufactured by the spunbonding method may belaminated and needle punched to form a laminated nonwoven fabric, andsaid laminated nonwoven fabric may be used as said nonwoven fabric ofthe present invention.

Said thermoplastic resin used as a material of said nonwoven fabric mayinclude such as polyethylene, polypropylene, ethylene-propylenecopolymer, ethylene-vinyl acetate copolymer, ethylene-propyleneterpolymer, polyvinyl chloride, polyvinylidene chloride, polystyrene,polyvinyl acetate, fluoroplastics, thermoplastic polyacrylate,thermoplastic polyester, thermoplastic polyamide,acrylonitrile-butadiene copolymer, butadiene-styrene copolymer,acrylonitrile-butadiene-styrene copolymer or the like.

Said thermoplastic resin may be used singly or two or more kinds of saidthermoplastic resin may be used together.

The thickness of said nonwoven fabric is commonly in the range ofbetween 0.05 mm and 1 mm, with the fineness of fiber composing saidnonwoven fabric being commonly in the range of between 0.05 dtex and 5dtex, the unit weight of said nonwoven fabric commonly being in therange of between 10 g/m²˜200 g/m².

A lot of holes are needle punched into said nonwoven fabric manufacturedby the spunbonding. The shape of said holes may vary circular,elliptical, rectangular, or the like. Not every hole formed in saidnonwoven fabric should necessarily be the same shape, and said holes mayvary between different kinds of shapes.

The diameter of each hole should be in the range of between 0.1 mm and 2mm, but desirably 0.2 mm and 1.5 mm. Herein, the diameter of the holemeans that in the case of a circle, the diameter is the diameter of thecircle, and in the case of a rectangular hole, the diameter is thelength of the longest diagonal line.

The number of holes is commonly in the range of between 10/cm² and100/cm². Synthetic resin is impregnated into said nonwoven fabric of thepresent invention. Said synthetic resin impregnated into said nonwovenfabric is a thermoplastic resin such as a phenol group resin, urethaneresin, melamine resin, urea resin, epoxy resin, thermosetting typepolyester resin, or the like. The phenol group resin used in the presentinvention is described below.

[Phenol Group Resin]

Phenol group resin is produced by the condensation reaction between aphenol group compound, and an aldehyde, and/or aldehyde donor. To givesaid phenol group resin water solubility, said phenol group resin may besulfomethylated and/or sulfimethylated.

Said phenol group resin is impregnated into said nonwoven fabric as aprecondensate. Usually, said precondensate is prepared as a watersolution but if desired, a water soluble organic solvent may be used.Said water soluble organic solvent is such as alcohol group solvent suchas methanol, ethanol, n-propanol, isopropanol, n-butanol, isobutanol,s-butanol, t-butanol, n-amyl alcohol, isoamyl alcohol, n-hexanol,methylamyl alcohol, 2-ethylbutanol, n-heptanol, n-octanol,trimethylnonyl alcohol, cyclohexanol, benzyl alcohol, furfuryl alcohol,tetrahydrofurfuryl alcohol, abiethyl alcohol, diacetone alcohol, or thelike, ketone group solvent such as acetone, methylacetone, ethyl methylketone, methyl n-propyl ketone, methyl n-butyl ketone, isobutyl methylketone, diethyl ketone, di-n-propyl ketone, diisobutyl ketone,acetonylacetone, methyl oxide, cyclohexanone, methylcyclohexanone,acetophenone, camphor, or the like, glycol group solvent such asethylene glycol, diethylene glycol, triethylene glycol, propyleneglycol, trimethylene glycol, polyethylene glycol, or the like, glycolether group solvent such as ethylene glycol monomethyl ether, ethyleneglycol monoethyl ether, ethylene glycol isopropyl ether, diethyleneglycol monomethyl ether, monomethyl triethylene glycol ether, or thelike, ester of said glycol group solvent or derivative thereof such asethylene glycol diacetate, diethylene glycol monoethyl ether acetate, orthe like, ether group solvent such as 1,4-dioxane, or the like, andfurther diethyl cellosolve diethylcarbitol, ethyl lactate, isopropyllactate, diglycol diacetate, dimethyl formamide, or the like.

(Phenol Group Compound)

The phenolic compound used to produce said phenolic resin may bemonohydric phenol, or polyhydric phenol, or a mixture of monohydricphenol and polyhydric phenol, but in a case where only monohydric phenolis used, formaldehyde is apt to be emitted when or after said resincomposition is cured, so that polyhydric phenol or a mixture ofmonohydric phenol and polyhydric phenol is preferably used.

(Monohydric Phenol)

The monohydric phenols include alkyl phenols such as o-cresol, m-cresol,p-cresol, ethylphenol, isopropylphenol, xylenol, 3,5-xylenol,butylphenol, t-butylphenol, nonylphenol, or the like; monohydric phenolderivatives such as o-fluorophenol, m-fluorophenol, p-fluorophenol,o-chlorophenol, m-chlorophenol, p-chlorophenol, o-bromophenol,m-bromophenol, p-bromophenol, o-iodophenol, m-iodophenol, p-iodophenol,o-aminophenol, m-aminophenol, p-aminophenol, o-nitrophenol,m-nitrophenol, p-nitrophenol, 2,4-dinitrophenol, 2,4,6-trinitrophenol,or the like; monohydric phenols of polycyclic aromatic compounds such asnaphthol, or the like. Each monohydric phenol can be used singly, or asa mixture thereof.

(Polyhydric Phenol)

The polyhydric phenols mentioned above, include resorcin, alkylresorcin,pyrogallol, catechol, alkylcatechol, hydroquinone, alkylhydroquinone,phloroglucinol, bisphenol, dihydroxynaphthalene, or the like. Eachpolyhydric phenol can be used singly, or as a mixture thereof. Resorcinand alkylresorcin are more suitable than other polyhydric phenols.Alkylresorcin, in particular, is the most suitable of polyhydricphenols, because it can react with aldehydes more rapidly than resorcin.

The alkylresorcins include 5-methylresorcin, 5-ethylresorcin,5-propylresorcin, 5-n-butylresorcin, 4,5-dimethylresorcin,2,5-dimethylresorcin, 4,5-diethylresorcin, 2,5-diethylresorcin,4,5-dipropylresorcin, 2,5-dipropylresorcin, 4-methyl-5-ethylresorcin,2-methyl-5-ethylresorcin, 2-methyl-5-propylresorcin,2,4,5-trimethylresorcin, 2,4,5-triethylresorcin, or the like.

A polyhydric phenol mixture produced by the dry distillation of oilshale, which is produced in Estonia, is inexpensive, said polyhydricphenol mixture including 5-metylresorcin, along with many other kinds ofalkylresorcin, being highly reactive, and making said polyhydric phenolmixture an especially desirable raw polyphenol material.

In the present invention, said phenolic compound and aldehyde and/oraldehyde donor (aldehydes) are condensed together. Said aldehyde donorrefers to a compound or a mixture which emits aldehyde when saidcompound or said mixture decomposes. The aldehydes include formaldehyde,acetaldehyde, propionaldehyde, chloral, furfural, glyoxal,n-butylaldehyde, capronaldehyde, allylaldehyde, benzaldehyde,crotonaldehyde, acrolein, phenylacetaldehyde, o-tolualdehyde,salicylaldehyde, or the like. The aldehyde donors includeparaformaldehyde, trioxane, hexamethylenetetramine, tetraoxymethylene,or the like.

As described above, said phenolic resin is desirably sulfoalkylatedand/or sulfialkylated, to improve the stability of said water solublephenolic resin.

(Sulfomethylation Agent)

The sulfomethylation agents used to improve the stability of the aqueoussolution of phenol resins, include such as water soluble sulfitesprepared by the reaction between sulfurous acid, bisulfurous acid, ormetabisulfirous acid, and alkaline metals, trimethylamine, quaternaryammonium (e.g. benzyltrimethylammonium); and aldehyde adducts preparedby the reaction between said water soluble sulfites and aldehydes.

The aldehyde adducts are prepared by the addition reaction betweenaldehydes and water soluble sulfites as mentioned above, wherein thealdehydes include formaldehyde, acetaldehyde, propionaldehyde, chloral,furfural, glyoxal, n-butylaldehyde, capronaldehyde, allylaldehyde,benzaldehyde, crotonaldehyde, acrolein, phenylacetaldehyde,o-tolualdehyde, salicylaldehyde, or the like. For example,hydroxymethane sulfonate, which is one of the aldehyde adducts, isprepared by the addition reaction between formaldehyde and sulfite.

(Sulfimethylation Agent)

The sulfimethylation agents used to improve the stability of the aqueoussolution of phenol resins, include alkaline metal sulfoxylates ofaliphatic or aromatic aldehyde such as sodium formaldehyde sulfoxylate(a.k.a. Rongalit), sodium benzaldehyde sulfoxylate, or the like;hydrosulfites (a.k.a. dithionites) of alkaline metal or alkaline earthmetal such as sodium hydrosulfite, magnesium hydrosulfite, or the like;hydroxyalkanesulfinate such as hydroxymethanesulfinate, or the like.

(Third Component)

In the case of producing said phenol resins, if necessary, additives maybe mixed in with said phenol resins as a catalyst or to adjust the pH.Such additives include acidic compounds and alkaline compounds. Saidacidic compounds include inorganic acid or organic acid such ashydrochloric acid, sulfuric acid, orthophosphoric acid, boric acid,oxalic acid, formic acid, acetic acid, butyric acid, benzenesulfonicacid, phenolsulfonic acid, p-toluenesulfonic acid,naphthalene-α-sulfonic acid, naphthalene-β-sulfonic acid, or the like;esters of organic acid such as dimethyl oxalate, or the like; acidanhydrides such as maleic anhydride, phthalic anhydride, or the like;salts of ammonium such as ammonium chloride, ammonium sulfate, ammoniumnitrate, ammonium oxalate, ammonium acetate, ammonium phosphate,ammonium thiocyanate, ammonium imidosulfonate, or the like; halogenatedorganic compounds such as monochloroacetic acid, the salt thereof,organic halogenides such as α,α′-dichlorohydrin, or the like;hydrochloride of amines such as triethanolamine hydrochloride, anilinehydrochloride, or the like; urea adducts such as the urea adduct ofsalicylic acid, urea adduct of stearic acid, urea adduct of heptanoicacid, or the like; and N-trimethyltaurine, zinc chloride, ferricchloride, or the like; alkaline compounds including ammonia, amines;hydroxides of alkaline metal and alkaline earth metal such as sodiumhydroxide, potassium hydroxide, barium hydroxide, calcium hydroxide, andthe like; oxide of alkaline earth metal such as lime, or the like; saltsof alkaline metal such as sodium carbonate, sodium sulfite, sodiumacetate, sodium phosphate, or the like.

(Method of Producing the Phenol Resins)

The phenol resins (the precondensation polymers) can be prepared usingthe usual method. The usual methods including method (a) comprising thecondensation of a monohydric phenol and/or a polyhydric phenol andaldehydes; method (b) comprising the condensation of a precondensationpolymer and a monohydric phenol and/or a polyhyrdric phenol, whereinsaid precondensation polymer comprises a monohydric phenol andaldehydes; method (c) comprising the condensation of a precondensationpolymer and a monohydric phenol and/or a polyhydric phenol, wherein saidprecondensation polymer comprises a monohydric phenol, a polyhydricphenol and aldehydes; method (d) comprising the condensation of aprecondensation polymer consisting of a monohydric phenol and aldehydes,with a precondensation polymer consisting of a polyhydric phenol andaldehydes; and method (e) comprising the condensation of aprecondensation polymer consisting of a monohydric phenol and aldehydesand/or precondensation polymers consisting of a polyhydric phenol andaldehydes, with a precondensation polymer consisting of a monohydricphenol and polyhydric phenol and aldehydes.

In the present invention, the desirable phenolic resin isphenol-alkylresorcin cocondensation polymer. Said phenol-alkylresorcincocondensation polymer provides a water solution of said cocondensationpolymer (pre-cocondensation polymer) having good stability, and beingadvantageous in that it can be stored for a longer time at roomtemperature, compared with a condensate consisting of a phenol only(precondensation polymer). Further, in a case where said water solutionis impregnated into said nonwoven fabric, after which said nonwovenfabric is precured to put said phenol resin at its B-stage, said phenolgroup resin at its B-stage in said nonwoven fabric may be stable, sothat said nonwoven fabric keeps a good moldability for a longtime.Further, since alkylresorcin is highly reactive to aldehyde, and catchesfree aldehyde to react with it, the content of free aldehyde in theresin can be reduced. Said phenol-alkylresorcin cocondensation polymeris also advantageous in that the content of free aldehyde in saidpolymer is reduced by the reaction with alkylresorcin.

The desirable method for producing said phenol-alkylresorcincocondensation polymer is first to create a reaction between phenol andaldehyde to produce a phenolic precondensation polymer, and then to addalkylresorcin, and if desired, aldehyde, to said phenolicprecondensation polymer to create a reaction.

In the case of method (a), for the condensation of monohydric phenoland/or polyhydric phenol and aldehydes, the aldehydes (0.2 mole to 3moles) are added to said monohydric phenol (1 mole), then said aldehydes(0.1 mole to 0.8 mole) are added to the polyhydric phenol (1 mole) asusual. If necessary, additives may be added to the phenol resins (theprecondensation polymers). In said method(s), there is a condensationreaction from heating at 55° C. to 100° C. for 8 to 20 hours. Theaddition of aldehydes may be made at one time at the beginning of thereaction, or several separate times throughout the reaction, or saidaldehydes may be dropped in continuously throughout the reaction.

In the case of sulfomethylation and/or sulfimethylation, thesulfomethylation agents and/or sulfimethylation agents may be added tothe precondensation polymers at an arbitrary time.

The addition of the sulfomethylation agents and/or sulfimethylationagents may be made any time, such as before, during, or aftercondensation. The total amount of said sulfomethylation agent and/orsulfimethylation agent added is usually in the range of between 0.001and 1.5 moles per 1 mole of phenol. In a case where said amount added isless than 0.001 mole, the hydrophile of the resulting sulfomethylatedand/or sulfimethylated phenolic resin is not adequate, and in a casewhere said amount added is more than 1.5 moles, the water resistance ofthe resulting sulfomethylated and/or sulfimethylated phenolic resindegrades. To provide excellent curing properties in the resultingprecondensate and excellent physical properties in the cured resin, saidamount to be added is preferably in the range of between 0.01 and 0.8mole per 1 mole of phenol.

The sulfomethylation agents and/or sulfimethylation agents forsulfomethylation and/or sulfimethylation react with the methylol groupsand/or aromatic groups, so that the sulfomethyl group and/or sulfimethylgroup are introduced to the precondensation polymers.

The solution of precondensation polymers of sulfomethylated and/orsulfimethylated phenol resins is stable even in a wide range of acidiccondition (e.g. pH=1.0) or alkaline condition, so that the solution canbe cured in any conditions such as acid, neutral or alkaline. In thecase of curing the precondensate under acidic condition, there is adecrease in the remaining methylol groups, so that no formaldehydes fromthe decomposed cured phenol resins appear.

Further, if necessary, the phenol resins and/or precondensation polymersthereof may be copolycondensed with amino resin monomers such as urea,thiourea, melamine, thiomelamine, dicyandiamine, guanidine, guanamine,acetoguanamine, benzoguanamine, 2,6-diamino-1,3-diamine, or the like.

Further, curing agents such as an aldehyde and/or an aldehyde donor oran alkylol triazine derivative, or the like, may be added to saidphenolic precondensation polymer (including precocondensation polymer).

As said aldehyde and/or aldehyde donor, the same aldehyde and/oraldehyde donor as used in the production of said phenolicprecondensation polymer is (are) used, and an alkylol triazinederivatives are produced by the reaction between urea group compound,amine group compound, and aldehyde and/or aldehyde donor. Said ureagroup compound used in the production of said alkylol triazinedderivatives may be such as urea, thiourea, and alkylurea such asmethylurea, an alkylthiourea such as methylthiourea; phenylurea,naphthylurea, halogenated phenylurea, nitrated alkylurea, or the like,or a mixture of two or more kinds of said urea group compounds. Aparticularly, desirable urea group compound may be urea or thiourea. Asthe amine group compounds, aliphatic amine such as methyl amine,ethylamine, propylamine, isopropylamine, butylamine, amylamine or thelike, benzylamine, furfuryamine, ethanolamine, ethylenediamine,hexamethylenediamine hexamethylenetetramine, or the like, as well asammonia are illustrated, and said amine group compound is used singly ortwo or more amine group compounds may be used together.

The aldehyde and/or aldehyde donor used for the production of saidalkylol triazine derivative is (are) the same as the aldehyde and/oraldehyde donor used for the production of said phenolic precondensationpolymer.

To synthesize said alkylol triazine derivatives, commonly 0.1 to 1.2moles of said amine group compound(s) and/or ammonia, and 1.5 to 4.0moles of aldehyde and/or aldehyde donor are combined to react with 1mole of said urea group compound.

In said reaction, the order in which said compounds are added isarbitrary, but preferably, first the required amount of aldehyde and/oraldehyde donor is (are) put in a reactor, then the required amount ofamine group compound(s) and/or ammonia is (are) gradually added to saidaldehyde and/or aldehyde donor, the temperature being kept at below 60°C., after which the required amount of said urea group compound(s) is(are) added to the resulting mixture, then said mixture is agitated andheated at 80 to 90° C. for 2 to 3 hours so as react together. Usually,37% by mass of formalin is used as said aldehyde and/or aldehyde donor,but some of said formalin may be replaced with paraformaldehyde toincrease the concentration of the reaction product.

Further, in a case where hexamethylenetetramine is used, the solidcontent of the reaction product obtained is much higher. The reactionbetween said urea group compound, said amine group compound and/orammonia and said aldehyde and/or aldehyde donor is commonly performed ina water solution, but said water may be partially or wholly replaced byone or more kinds of alcohol(s) such as methanol, ethanol, isopropanol,n-butanol, ethylene glycol, diethylene glycol, or the like, and one ormore kinds of other water soluble solvent(s) such as a ketone groupsolvent like acetone, ethyl methyl ketone, or the like can also be usedas solvents.

The amount of said curing agent to be added is, in the case of analdehyde and/or aldehyde donor, in the range of between 10 and 100 partsby mass to 100 parts by mass of said phenolic precondensation polymer(precopolycondensation polymer), and in the case of alkylol triazine, 10to 500 parts by mass to 100 parts by mass of said phenolicprecondensation polymer (precopolycondensation polymer).

Said synthetic resin is commonly prepared as a solution and one or morekind(s) of third component(s) may be added to said solution. Said thirdcomponent is, for example, water-soluble polymer and natural gums suchas poly(vinyl alcohol), sodium alginate, starch, starch derivatives,glue, gelatin, blood powder, methylcellulose, carboxymethylcellulose,polyacrylate, polyacrylamide or the like; fillers and surfactants suchas calcium carbonate, magnesium carbonate, barium sulfate, calciumsulfite, calcium phosphate, calcium hydroxide, magnesium hydroxide,aluminum hydroxide, magnesium oxide, titanium oxide, iron oxide, zincoxide, alumina, silica, diatom earth, dolomite, gypsum, talc, clay,asbestos, mica, calcium silicate, bentonite, white carbon, carbon black,iron powder, aluminum powder, glass powder, stone powder, syntheticresin powder, blast furnace slag, fly ash, cement, zirconia powder, woodflour, wheat flour, walnut flour, coconut flour, ground rice, or thelike; higher fatty acid such as stearic acid, palmitic acid, or thelike; higher alcohol such as palmityl alcohol, stearyl alcohol, or thelike; carboxylic ester such as butyl stearate, glycerol, monostearate orthe like; carboxylic amide; natural wax and synthetic wax such ascarnauba wax, or the like; pigment, dye, burning retardant, flameretardant, insecticide, antiseptic agent, age resister, ultravioletabsorber, fluorescent dye, surfactant, foaming agent, oil repellentagent, or the like.

In a case where said thermosetting resin is impregnated into saidnonwoven fabric, said nonwoven fabric may be dried after theimpregnation of said resin, to put said resin in said nonwoven fabric atits B-stage.

A powder or film of hot-melt adhesive may be applied or laminated ontosaid nonwoven fabric. Said hot-melt adhesive is, for example, apolyolefin resin such as polyethylene, polypropylene, ethylene-vinylacetate copolymer, or a modified polyolefin resin, polyvinyl chloride,polyurethane, polyester, ester copolymer, polyamide, polyamidecopolymer, cellulose derivative, polyvinylether, or the like.

Said elastic nonwoven fabric (1) of the present invention has a lot ofholes (2) from needle punching, as shown in FIG. 1, so that theelasticities along the length and width of said nonwoven fabric areimproved by said holes, and accordingly, said nonwoven fabric is easilyattached to other material without forming wrinkles, even in a casewhere said nonwoven fabric is attached to parts having an unevensurface,

Said parts to which said nonwoven fabric is attached have a desirableappearance. Said elastic nonwoven fabric (1) is used for a surface layer(2) of an interior (3).

Said nonwoven fabric of the present invention is manufactured by thespunbonding method, but in the present invention, a nonwoven fabricmanufactured by the melt-blow method or the calendar treatment can beused.

[Interior]

An interior can be manufactured by attaching said elastic nonwovenfabric of the present invention to a base material as a surface layer,then molding said base material onto which said elastic nonwoven fabricis attached, into a prescribed shape.

As said base material, knitted or woven fabric, nonwoven fabric, feltand laminated fabrics thereof, foamed plastics having connected cells,sintered plastic beads, or the like are used. Said fabric is made of asynthetic fiber such as polyester fiber, polyethylene fiber,polypropylene fiber, polyamide fiber, acrylic fiber, polyurethane fiber,polyvinyl chloride fiber, polyvinylidene chloride fiber, acetate fiber,or the like, botanical fiber such as pulp, cotton, coconut fiber, hemp,bamboo fiber, kenaf fiber, or the like, inorganic fiber such as glassfiber, carbon fiber, ceramics fiber, asbestos fiber, or the like, orrecycled fiber from the scrap of the products made of said fiber, or afiber mixture containing two or more kinds of said fibers.

Said foamed plastic is made of plastic such as polyurethane (flexiblepolyurethane, rigid polyurethane), polyethylene, polypropylene,polyamide, polyester, polyvinyl chloride, or the like.

A synthetic resin may be impregnated into said base material. Saidsynthetic resin includes thermoplastic resins such as polyethylene,polypropylene, ethylene-propylene copolymer, ethylene-vinyl acetatecopolymer, polyvinyl chloride, polyvinylidene chloride, polystyrene,polyvinyl acetate, fluoride resin, thermoplastic acrylic resin,thermoplastic polyester resin, thermoplastic polyamide resin,acrylonitrile-butadiene copolymer, butadiene-styrene copolymer,acrylonitrile-butadiene-styrene copolymer, or the like, andthermosetting resin such as urethane resin, melamine resin, urea resin,thermosetting acrylic resin, phenol resin, resorcinol resin,alkylresorcinol resin, epoxy resin, thermosetting polyester, or thelike.

In a case where said thermosetting resin is impregnated, said basematerial into which said thermosetting resin is impregnated ispreferably dried, to put said thermosetting resin at its B-stage.

To attach said surface layer made of said elastic nonwoven fabric tosaid base material, said surface layer is put on said base material,after which said base material is hot-pressed or heated, and thencold-pressed.

In the case of molding said base material onto which said surface layeris attached, said base material is preferably molded at the same timethat said surface layer is attached to said base material.

In a case where said base material is molded concurrently to when saidsurface layer is attached, said surface layer is attached to said baselayer with enough elasticity to give the resulting molded interior agood appearance.

The resulting interior may be used for automobile parts such as the doortrim, dashboard, head lining, hood insulator, engine cover, or the like,or as an automobile heat insulating material and sound proof material,building material, wall material, building heat insulating material,building sound proof material, or the like.

The present invention is explained in the EXAMPLES described below, andfurther, the present invention is not limited to the specific EXAMPLESdescribed below.

EXAMPLE 1

A nonwoven fabric made of a polyester fiber (fineness: 3.5 dtex, unitweight: 40 g/m²) was manufactured by the spunbonding method.

To form a lot of holes in said nonwoven fabric, said nonwoven fabric waspressed by a needle roller on whose surface a lot of needles wererandomly arranged, each needle having a maximum diameter of 1 mm. Theresulting nonwoven fabric had a lot of holes, the diameter of each ofsaid holes being in the range of between 0.1 mm and 0.3 mm, with 15holes being formed per 1 cm² of said nonwoven fabric.

Further, a phenol-formaldehyde precondensate (solid content 30% by mass)was impregnated into said hole punched nonwoven fabric in an amount of30% by mass as solid content. After impregnating with saidprecondensate, said nonwoven fabric was dried at 150° C. for 3 minutesfor precuring, to obtain an elastic nonwoven fabric.

EXAMPLE 2

An elastic nonwoven fabric was manufactured in the same manner as inEXAMPLE 1, with the exception that a lot of holes were formed, each holehaving a diameter in the range of between 0.1 mm and 0.3 mm, with 50such holes being formed per 1 cm² of said nonwoven fabric.

EXAMPLE 3

An elastic nonwoven fabric was manufactured in the same manner as inEXAMPLE 1, with the exception that a lot of holes were formed, each holehaving a diameter in the range of between 0.1 mm and 0.3 mm, with 100holes being formed per 1 cm² of said nonwoven fabric.

COMPARISON 1

An elastic nonwoven fabric was manufactured in the same manner as inEXAMPLE 1, with the exception that a lot of holes were formed, each holehaving a diameter in the range of between 0.1 mm and 0.3 mm, with 8holes being formed per 1 cm² of said nonwoven fabric.

COMPARISON 2

An elastic nonwoven fabric was manufactured in the same manner as inEXAMPLE 1, with the exception that a lot of holes were formed, each holehaving a diameter in the range of between 0.1 mm and 0.3 mm, with 110holes being formed per 1 cm² of said nonwoven fabric.

Test

Said elastic nonwoven fabrics (1) manufactured in EXAMPLES 1 to 3, andCOMPARISONS 1 and 2, were each used as surface layers (1A).

A phenol-formaldehyde precondensate was coated onto a glass wool sheet(7) as a base material, and said glass wool mat (7) (unit weight: 800g/m², thickness: 50 mm) on which said phenol-formaldehyde precondensatewas coated was then precured, and each surface layer (1A) was put onsaid precured base material (7), and each precured base material (7)upon which each surface layer (1A) was put was then respectively moldedwith a mold (3) consisting of an upper mold (4) and a lower mold (5), asshown in FIG. 2, at 200° C. for 60 seconds, to manufacture a moldedarticle (6) (thickness 5 mm), as shown in FIG. 3.

The appearance of each molded article (6) was observed optically. Theresults are shown in Table 1.

TABLE 1 Number of Holes Appearance of Molded Sheet(6) Molded Sheet(6)(per 1 cm²) (Surface Layer in particular (1A)) EXAMPLE 1 15 No wrinkles,no peeling, good appearance EXAMPLE 2 50 No wrinkles, no peeling, goodappearance EXAMPLE 3 100 No wrinkles, no peeling, good appearanceCOMPARISON 1 8 Wrinkles occur on the corner part(9) of the molded sheetCOMAPRISON 2 110 Peeling of nonwoven fabric on the incline part(8)

EXAMPLE 4

A nonwoven fabric made of a polypropylene fiber (fineness: 0.1 dtex unitweight: 30 g/m²) was manufactured by the spunbonding method.

To form a lot of holes in said nonwoven fabric, said nonwoven fabric waspressed by a needle roller on whose surface a lot of needles wererandomly arranged, each needle having a maximum diameter of 1 mm. Theresulting nonwoven fabric had a lot of holes, the diameters of saidholes being in the range of between 0.8 mm and 1.2 mm, with 25 holesbeing formed per 1 cm² of said nonwoven fabric.

Further, a phenol-formaldehyde precondensate (solid content: 40% bymass) was impregnated into said holepunched nonwoven fabric in an amountof 25% by mass as a solid. After impregnating with said precondensate,said nonwoven fabric was dried at 150° C. for 3 minutes for precuring,to obtain an elastic nonwoven fabric.

Said nonwoven fabric, used as a surface layer, was put on a basematerial, said base material being manufactured by coating a phenolformaldehyde precondensate onto a glass wool mat (unit weight 600 g/m²,thickness: 40 mm) and precuring said glass wool mat upon which saidphenol formaldehyde precondensate was coated. Said base material uponwhich said surface layer was put was then molded at 210° C. for 45seconds into a prescribed shape by the hot-press method, to obtain amolded article. Said molded article has no wrinkles and no other defectsin appearance.

EXAMPLE 5

A nonwoven fabric made of a polyester fiber (fineness: 2.0 dtex, unitweight: 60 g/m²) was manufactured by the spunbonding method. To form alot of holes in said nonwoven fabric, said nonwoven fabric was pressedby a needle roller on whose surface a lot of needles were randomlyarranged, each needle having a maximum diameter of 1 mm. The resultingnonwoven fabric had a lot of holes, the diameters of said holes being inthe range of between 0.5 mm and 0.8 mm, with 18 holes being formed per 1cm² of said nonwoven fabric.

Further, a phenol-alkylresorcine-formaldehyde precondensate used inEXAMPLES 4 (solid content: 40% by mass) was impregnated into saidholepunched nonwoven fabric in an amount of 30% by mass as a solid,after which a polyamide group hot-melt adhesive powder (200 mesh pass,melting point 130° C.) was sprayed on the reverse side of said nonwovenfabric. Following this, said nonwoven fabric was heated at 150° C. for 2minutes, to obtain an elastic nonwoven fabric on whose reverse side saidhot-melt adhesive powder was applied.

COMPARISON 3

An elastic nonwoven fabric was manufactured in the same manner as inEXAMPLE 5, with the exception that a lot of holes, each having adiameter in the range of between 2.1 mm and 2.4 mm, were formed in saidnonwoven fabric.

COMPARISON 4

A nonwoven fabric (unit weight: 60 g/m²) made of a fiber mixturecontaining 90% by mass of said polyester fiber used in EXAMPLE 5, and10% by mass of a low melting point polyester fiber (fineness: 2.0 dtex,softening point: 110° C.) was manufactured by needle punching (unitweight: 60 g/m²).

Said phenol-alkylresorcine-formaldehyde precondensate used in EXAMPLE 5(40% by mass as a solid) was impregnated into said nonwoven fabric in anamount of 30% by mass as a solid, after which said polyamide grouphot-melt adhesive powder used in EXAMPLE 5 was sprayed onto saidnonwoven fabric, into which said precondensate was impregnated.

Following this, said nonwoven fabric was dried at 150° C. for 2 minutes,to obtain an elastic nonwoven fabric upon which said hot-melt adhesivepowder was applied.

Each elastic nonwoven fabric manufactured in EXAMPLE 5 and COMPARISONS 3and 4 were used for a surface layer. Each surface layer was put on aglass wool mat onto which a phenol formaldehyde precondensate was coatedand precured (unit weight: 1000 g/m², thickness 70 mm), and said glasswool mat, upon which said nonwoven fabric was put, was molded into aprescribed shape by the hot-press method at 200° C. for 50 seconds, toobtain a molded article. The appearance of each molded article wasobserved optically. The results are shown in Table 2.

TABLE 2 Appearance of molded article Sample (surface layer inparticular) EXAMPLE 5 No wrinkles, no peeling, no snags in the surfacelayer, very good appearance COMPARISON 3 Snags in the uneven part of themolded base material COMPARISON 4 Good moldability, but noticeable fluffin the surface layer of the thick area of the molded base part

Since nonwoven fabric manufactured by the traditional spunbonding methodhas poor elasticity along its length and width, it is recognized thatwrinkles easily occur in the surface layer of the uneven area of thebase material when said nonwoven fabric is attached to said basematerial as a surface layer, and further, that said surface layer iseasy to remove from the uneven part of said base material (defectivebonding).

Further, nonwoven fabric manufactured by the needle punching method hasa good elasticity along its length and width, so that said nonwovenfabric (surface layer) attaches well to the base material, but, sincefluffs occur on the surface of said nonwoven fabric, the appearance ofthe resulting molded article is imperfect.

The molded article using said elastic nonwoven fabric of the presentinvention as a surface layer has an excellent appearance and goodmoldability.

POSSIBILITY OF INDUSTRIAL USE

The elastic nonwoven fabric of the present invention can be used for thesurface layer of an automobile interior, for such as the door trim, headlining, hood insulator, engine cover, or the like, as a surface layerfor an automobile heat insulating material, or sound proof material, asurface layer for building material, wall material, building heatinsulating material, building sound proof material, or the like.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the elastic nonwoven fabric.

FIG. 2 is a sectional view illustrating the mold.

FIG. 3 is a sectional side view of the molded article.

-   1. nonwoven fabric-   2. hole

1. An elastic nonwoven fabric made of a nonwoven fabric manufactured bya spunbonding method, wherein a multiplicity of holes are formed in saidnonwoven fabric by a needle punching method, and synthetic resin isimpregnated into said nonwoven fabric.
 2. (canceled)
 3. An elasticnonwoven fabric in accordance with claim 1 wherein said synthetic resincomprises a thermoplastic resin.
 4. An interior material for anautomotive vehicle, said material comprising a nonwoven fabric inaccordance with claim 1, as a surface layer material, and a basematerial having a surface to which said elastic nonwoven fabric isattached as a surface layer, then being molded into a prescribed shape.5. An interior material for an automotive vehicle, said materialcomprising a nonwoven fabric in accordance with claim 2, as a surfacelayer material, and a base material having a surface to which saidelastic nonwoven fabric is attached as a surface layer, then beingmolded into a prescribed shape.
 6. An interior material for anautomotive vehicle, said material comprising a nonwoven fabric inaccordance with claim 3, as a surface layer material, and a basematerial having a surface to which said elastic nonwoven fabric isattached as a surface layer, then being molded into a prescribed shape.7. An elastic nonwoven fabric in accordance with claim 1, wherein saidholes range in number between substantially 10/cm² and 100/cm².
 8. Anelastic nonwoven fabric in accordance with claim 1 having a weightwithin the range of substantially 30 g/m² to 60 g/m².
 9. an elasticnonwoven fabric in accordance with claim 1, wherein each of said holeshas a diameter within the range of 0.1 mm to 2.4 mm.